Composite aerostructure with integrated heating element

ABSTRACT

A heated composite structure and a method for forming a heated composite structure. The structure includes carbon fibers embedded within a thermoplastic matrix. The carbon fibers are connected with first and second electrodes that are configured to be connected with an electric source such that applying current to the electrodes causes current to flow through the embedded carbon fibers to provide resistive heating sufficient to heat the composite structure to impede formation of ice on the composite structure.

PRIORITY CLAIM

This application is a divisional application of co-pending U.S. patentapplication Ser. No. 16/393,519 filed on Apr. 24, 2019 which claimspriority to U.S. Provisional Patent Application No. 62/661,917 filed onApr. 24, 2018. The entire disclosure of each of the foregoingapplications is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the field of composite materials. Inparticular, the present application relates to composite materials thatincorporate an integrated heating assembly. The present invention findsparticular application to the field of ice protection systems forcomposite aerostructures.

BACKGROUND

Ice build-up on aircraft surfaces can cause dangerous in flightsituations and has led to numerous fatalities over the years. Onstructures such as the airframe, airfoils, wings, etc. icing leads toincreased weight, increased drag and decreased lift. On structures suchas engine intakes, icing on the leading edge can create flow problemsand lead to ice ingestion, which can degrade operation of the engine ordamage components of the engine.

To prevent the dangers associated with icing, numerous ice protectionsystems have been developed over the years to protect the aircraft fromicing and/or to shed ice from the surfaces if ice accumulates. Theprimary ice protection system in use today are bleed air systems thatre-directs a portion of the compressed air from the engine before theair enters the combustion chamber. The compressed air is pressurized hotair that is used to heat up surfaces of the aircraft to prevent thebuild-up of ice. Although bleed air systems are effective, they reducethe efficiency of the engines and increase the weight of the aircraft.Accordingly, there has been a long felt need for an ice protectionsystem that does not suffer from the drawbacks of the known systems.

SUMMARY OF THE INVENTION

In light of the foregoing, according to an aspect of the presentinvention, a heated aerostructure is provided. The heated aerostructureincludes a composite structure that comprises a carbon fiber reinforcedthermoplastic upper layer, a carbon fiber reinforced thermoplastic lowerlayer and a carbon fiber reinforced thermoplastic heater layer. Theheater layer includes a plurality of electrically conductive carbonfibers, a first electrode electrically connected with the conductivecarbon fibers, and a second electrode electrically connected with theconductive carbon fibers. The conductive carbon fibers provide anelectrical pathway between the first electrode and the second electrode.The aerostructure also includes a controller connected with anelectrical power source for controlling the power provided to the firstelectrode. The first electrode and the electrically conductive carbonfibers are connected such that electric power applied to the firstelectrode is conducted to the electrically conductive carbon fibers toprovide resistive heating sufficient to heat the composite structure toimpede formation of ice on the composite structure.

According to a further aspect, the present invention provides a heatedaerostructure having a controller that is operable to control theelectrical power provided to the first electrode in response to signalsreceived from a sensor that detects a characteristic indicative of thepresence of ice on the aerostructure.

Still further, the present invention provides a heated aerostructurehaving an upper layer comprises a semicrystalline thermoplastic in thepolyaryletherketone family. Similarly, the present invention provides aheated aerostructure having a lower layer that comprises asemicrystalline thermoplastic in the polyaryletherketone family.

Further yet, the present invention provides a heated aerostructurewherein the heater layer and at least one of an upper layer and a lowerlayer comprise similar thermoplastic.

According to a further aspect, the present invention provides a heatedaerostructure having a heater layer, an upper layer and a lower layerthat comprise a semicrystalline thermoplastic in the polyaryletherketonefamily.

According to yet another aspect, the present invention provides a heatedaerostructure comprising a first electrically insulative layerinsulating an upper layer from the heater layer. Similarly, the presentinvention also provides a heated aerostructure comprising a secondelectrically insulative layer insulating the lower layer from the heaterlayer. Optionally, one or both of the first and second electricallyinsulative layers may comprise thermoplastic. Further, optionally, thefirst electrically insulative layer comprises a composite materialcomprising reinforcing fibers embedded within the thermoplastic.

According to still another aspect, the present invention provides aheated aerostructure that includes a first electrode that comprises ametallic mesh embedded within a thermoplastic of a heater layer.

According to another aspect, the present invention provides a heatedaerostructure comprising a composite structure that forms a portion ofan airfoil.

According to a further aspect, the present invention provides a heatedaerostructure comprising a composite structure that forms a portion of anacelle.

According to yet another aspect, the present invention provides a heatedaerostructure having an upper layer comprising a plurality of carbonfiber reinforced thermoplastic lamina. Similarly, the present inventionprovides a heated aerostructure that may have a lower layer comprises aplurality of carbon fiber reinforced thermoplastic lamina. Optionally,the thermoplastic of each of the heater layer, the upper layer and thelower layer are fused with the thermoplastic in adjacent layers.

According to another aspect, the present invention provides a heatedaerostructure that includes a composite structure formed of a reinforcedthermoplastic upper layer, a reinforced thermoplastic lower layer, and areinforced thermoplastic heater layer. The heater layer includes aplurality of electrically conductive non-metallic fibers, a firstelectrode electrically connected with the conductive non-metallicfibers, and a second electrode electrically connected with theconductive non-metallic fibers, so that the conductive non-metallicfibers provide an electrical pathway between the first electrode and thesecond electrode. A sensor detects a characteristic indicative of iceformation on the composite structure and a controller connected with thesensor and an electrical power source controls the power provided to thefirst electrode. The first electrode and the conductive non-metallicfibers are connected such that electric power applied to the firstelectrode is conducted to the electrically conductive non-metallicfibers to provide resistive heating sufficient to heat the compositestructure to impede formation of ice on the composite structure.

According to yet another aspect, the present invention provides a heatedcomposite structure that includes a carbon fiber reinforcedthermoplastic upper layer, a carbon fiber reinforced thermoplastic lowerlayer, and a carbon fiber reinforced thermoplastic heater layer. Theheater layer may include a plurality of electrically conductive carbonfibers, a first electrode electrically connected with the conductivecarbon fibers, and a second electrode electrically connected with theconductive carbon fibers, so that the conductive carbon fibers providean electrical pathway between the first electrode and the secondelectrode. The first electrode and the electrically conductive carbonfibers are connected such that electric power applied to the firstelectrode is conducted to the electrically conductive carbon fibers toprovide resistive heating sufficient for the heating layer to achieve atemperature increase of at least 50 degrees Fahrenheit or approximately30 degrees Celsius. Optionally, the carbon fibers of the heater layerare connected with the first electrode such that electric power appliedto the first electrode is conducted to the electrically conductivecarbon fibers to provide resistive heating sufficient for the heatinglayer to achieve a temperature increase of 100 degrees Fahrenheit orapproximately 55 degrees Celsius. Further still, the carbon fibers ofthe heater layer may be connected with the first electrode such thatelectric power applied to the first electrode is conducted to theelectrically conductive carbon fibers to provide resistive heatingsufficient for the heating layer to achieve a temperature increase of200 degrees Fahrenheit or approximately 110 degrees Celsius.

According to another aspect, the present invention provides a method forforming a heated composite structure. The method includes the steps ofproviding a plurality of carbon fibers embedded within a thermoplasticmatrix and electrically connecting the carbon fibers with first andsecond electrodes to form a heater layer. The method further includesthe steps of heating the heating layer above the melting temperature ofthe thermoplastic matrix and heating a plurality of layers of reinforcedthermoplastic laminae. The thermoplastic in the laminae have a meltingtemperature and the step of heating the plurality of layers comprisesheating the layers above the melting temperature of the thermoplastic inthe laminae. Additionally, the method includes the step of applying theheated plurality of layers to the heated heating layer so that theheater is fused with the plurality of layers after the heater layer andthe plurality of layers cool.

According to yet another aspect, the present invention provides a methodof heating a composite structure. The method includes the step ofproviding a composite structure formed of a carbon fiber reinforcedthermoplastic layer, wherein the carbon fibers are connected with firstand second electrodes. The first and second electrodes are connected toan electric source and the flow of electricity from the electric sourceto the first electrode is controlled so that the electricity flows fromthe first electrode to the carbon fibers to the second electrode toprovide resistive heating sufficient to heat the composite structure.

According to a further aspect, the present invention provides a methodof heating a composite structure wherein the step of controllingcomprises controlling the flow of electricity to provide resistiveheating sufficient to heat the composite structure to impede formationof ice on the composite structure.

According to still another aspect, the present invention provides amethod that include the step of monitoring the temperature of thecomposite structure and a step of controlling comprises controlling theflow of electricity in response to the step of monitoring.

According to yet another aspect, the present invention provides a heatedcomposite structure that includes a carbon fiber reinforcedthermoplastic upper layer, a carbon fiber reinforced thermoplastic lowerlayer, and a carbon fiber reinforced thermoplastic heater layer. Theupper layer, lower layer and heater layer are consolidated to form alaminate. The heater layer comprises a plurality of electricallyconductive carbon fibers and the heater layer is configured so that theelectrically conductive carbon fibers of the heater layer areconnectable with a power source so that electricity can flow through theelectrically conductive carbon fibers of the heater layer to provideresistive heating sufficient for the heating layer to heat at least aportion of the laminate at least approximately 50 degrees Fahrenheit or30 degrees Celsius. Optionally, the structure includes a sensor operableto sense a characteristic indicative of ice forming on an outer surfaceof the laminate. Additionally, the structure may optionally include acontroller connected with the sensor and an electrical power source forcontrolling the power provided to the heater layer. Still further, thestructure may optionally include first and second electrodes embeddedwithin the laminate in electrical contract with the electricallyconductive carbon fibers such that electric power applied to the firstelectrode is conducted to the electrically conductive carbon fibers toprovide resistive heating sufficient to heat the composite structure toimpede formation of ice on the composite structure. Additionally, thecontroller may be operable to control the electrical power provided toheater layer in response to signals received from the sensor.

While the methods and apparatus are described herein by way of examplefor several embodiments and illustrative drawings, those skilled in theart will recognize that the inventive aerostructure with integratedheating element and method method for making such an aerostructure arenot limited to the embodiments or drawings described. It should beunderstood, that the drawings and detailed description thereto are notintended to limit embodiments to the particular form disclosed. Rather,the intention is to cover all modifications, equivalents andalternatives falling within the spirit and scope of the methods andapparatus for sorting items using one or more dynamically reconfigurablesorting array defined by the appended claims. Any headings used hereinare for organizational purposes only and are not meant to limit thescope of the description or the claims. As used herein, the word “may”is used in a permissive sense (i.e., meaning having the potential to),rather than the mandatory sense (i.e., meaning must). Similarly, thewords “include”, “including”, and “includes” mean including, but notlimited to.

DESCRIPTION OF THE DRAWINGS

The foregoing summary and the following detailed description of thepreferred embodiments of the present invention will be best understoodwhen read in conjunction with the appended drawings, in which:

FIG. 1 is a diagrammatic perspective view of a composite structure withan integrated heating assembly;

FIG. 2 is a plan view of the heating assembly of the composite structureillustrated in FIG. 1;

FIG. 3. is a diagrammatic view of a system incorporating the compositestructure illustrated in FIG. 1;

FIG. 4 is a partially broken away perspective view of a compositeaerostructure incorporating an integrated heating assembly;

FIG. 5 is an exploded perspective view of the composite aerostructureillustrated in FIG. 4;

FIG. 6 is an exploded perspective view of an alternate compositeaerostructure incorporating an integrated heating assembly;

FIG. 7 is a plan view of a heating layer of the aerostructureillustrated in FIG. 6;

FIG. 8 is a plan view of a heating zone of the heating layer illustratedin FIG. 7; and

FIG. 9 is a perspective view of a portion of the heating layerillustrated in FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the figures in general, and to FIGS. 1-3 in particular,a system that incorporates a composite structure with an integratedheating assembly is designated generally 10. The system includes alaminate 20, a power source 60 and a controller 70 that controls thepower provided to the laminate. The laminate includes structural layers25, 26 and a heating assembly 30. The heating layer 30 may be configuredto provide sufficient heat to the structure to heat the upper and/orlower surface of the laminate 20.

Referring now to FIG. 1, the details of the laminate 20 will bedescribed in greater detail. The laminate 20 includes a heating element30 embedded within structural layers. In particular, the heating element30 is sandwiched between an upper structural layer 25 and a lowerstructural layer 26. The upper and lower structural layers 25, 26 areeach formed of one or more plies of a composite lamina. In the presentinstance, each structural layer comprises a plurality of compositelaminae. Each composite lamina comprises reinforcing elements embeddedwithin a matrix material. Depending upon the application, thereinforcing elements may be any of a variety of reinforcing materials.By way of example, the reinforcing elements may be elongated strands orfibers of glass or carbon. For instance, an exemplary carbon fiber is acontinuous, high strength, high strain, PAN based fiber in tows of 3,000to 12,000. In particular, in the present instance, the reinforcingelements are carbon fibers produced by Hexcel Corporation of Stamford,Conn. and sold under the name HEXTOW, such as HEXTOW AS4D. Thesereinforcing fibers may be treated with a surface treatment and may besized to improve their interlaminar shear properties with the matrixmaterial. However, it should be understood that these materials areintended as exemplary materials; other materials can be utilizeddepending on the environment in which the laminate is to be used.

The reinforcing elements are embedded within a matrix material, such asa polymer. Depending on the application, any of a variety of polymerscan be used for the matrix material, including amorphous, crystallineand semi-crystalline polymers. In the present instance, the matrixmaterial is a thermoplastic material, such as a thermoplastic elastomer.More specifically, the thermoplastic material is a semi-crystallinethermoplastic. In particular, the thermoplastic may be a thermoplasticpolymer in the polyaryletherketone (PAEK) family, including, but notlimited to polyetheretherketone (PEEK) and polyetherketoneketone (PEKK).

As noted above, the structural layers 25, 26 are formed of one or morecomposite laminae, which may be carbon fiber reinforced thermoplasticcomposites. In particular, the lamina may be thermoplastic prepregs,which are laminae in which the reinforcement materials have beenpre-impregnated with resin. For instance, the prepreg may bethermoplastic prepregs produced by coating fiber reinforcement with athermoplastic matrix. Such a prepreg lamina has the ability to bereheated and reformed by heating the lamina above the melting point ofthe thermoplastic matrix. Several exemplary prepreg materials that maybe used to form the structural elements 25, 26 include, but are notlimited to, materials produced by TenCate Advanced Composites USA ofMorgan Hill, Calif. and sold under the name CETEX, such as TC1200,TC1225 and TC1320. TC1200 is a carbon fiber reinforced semi-crystallinePEEK composite having a glass transition temperature (T_(g)) of 143°C./289° F. and a melting temperature (T_(m)) of 343° C./649° F. TC1225is a carbon fiber reinforced semi-crystalline PAEK composite having aT_(g) of 147° C./297° F. and a T_(m) of 305° C./581° F. TC1320 is acarbon fiber reinforced semi-crystalline PEKK composite having a T_(g)of 150° C./318° F. and a T_(m) of 337° C./639° F.

Referring again to FIG. 1, the laminate comprises a heating layer 30disposed between the upper and lower structural layers 25, 26. Thestructural layers are formed of composite lamina and are configured tocarry the structural load. Although the heating layer may be configuredto carry structural load, in the present instance, the heater layer 30is configured to heat the laminate 20 without carrying significant, ifany, structural load. In particular, the heating layer 30 is configuredto provide sufficient heat to raise the temperature of the upper surface22 and/or the lower surface 23 of the laminate.

The heating layer 30 is configured to provide resistive heating bypassing current through one or more resistive elements 40, which operateas the heating element. The resistive elements 40 are electricallyconductive, but provide sufficient electrical resistance to provideresistive heating when current is applied. A variety of resistiveelements may be incorporated into the heating layer 30, however, in thepresent instance, the resistive elements are formed of a non-metallicelement. Further still, the heating element may be the same orsubstantially similar to the reinforcing elements in one or both of thestructural layers 25, 26. For instance, in the present instance, theresistive elements 40 are carbon fibers. Specifically, the resistiveelements 40 are carbon fibers, such as the continuous, high strength,high strain, PAN based fibers described above in connection with thestructural layers 25, 26.

Referring to FIGS. 1-2, the resistive elements 40 are connected with aninput electrode 50 and an output electrode 52. The resistive elements 40provide a continuous path between the first and second electrodes 50,52. The resistive elements 40 are oriented in the laminate 20 to heat atleast a portion of the laminate along the length of the laminate. In thepresent instance, the resistive elements 40 are carbon fibers and thefibers are oriented to form a serpentine pattern through the length ofthe laminate. Although each resistive element may extend the lengthand/or width of the laminate, in the present instance, the resistiveelements extend a portion of the length of the laminate. For instance, afirst resistive element 40 a has a first end 42 a connected with thefirst electrode 50 and a second end 44 a connected with the secondelectrode 52. Similarly, additional resistive elements 40 b, 40 c extendbetween electrodes 50, 52.

In the foregoing description, each resistive element 40 a, 40 b, 40 c isdescribed as an individual element, however, it should be understoodthat each resistive element may comprise a plurality of separateresistive elements. In particular, when the resistive elements arecarbon fibers, each resistive element may comprise hundreds or thousandsof individual strands or fibers that extend along the length of theresistive element.

The carbon fiber resistive elements 40 are embedded within a matrixmaterial. Preferably, the matrix material is a thermoplastic materialthat can be heat fused with the other layers in the laminate. By heatfusing the matrix material of the heating layer, the heating layer isintegrally formed with the laminate. In particular, in the presentinstance, the heating assembly is formed of a composite material that issubstantially similar to the composite material forming the structurallayers 25, 26. For instance, the resistive elements are carbon fibersand the matrix material is a thermoplastic material, such as asemi-crystalline thermoplastic in the polyaryletherketone (PAEK) family.Additionally, in the present instance, the resistive elements are formedfrom a lamina of unidirectional carbon fiber material. Theunidirectional fibers are formed into a plurality of segments that areinterconnected to form continuous resistive elements from the first end42 to the second end 44. In the present instance, the individualsegments of each resistive element are interconnected by conductiveelements, such as copper. Additionally, although the present embodimentincorporates unidirectional fibers, it should be understood that theresistive element may be formed of a plurality of continuous strands orfibers of conductive material. For instance, the resistive element maycomprise a plurality of continuous carbon fibers in which the carbonfibers are not straight, but instead form curved elements, similar tothe serpentine pattern shown in FIG. 2. For example, the carbon fibersmay be formed in a wavy composite in which the fibers are laid out in aperiodic wave pattern, similar to a sine wave.

If the resistive elements 40 are carbon fibers, the carbon fibers may becoated with a sizing material to improve the bonding between the carbonfibers and the matrix material. However, the sizing material may tend toelectrically insulate the carbon fibers from making electricalconnection with the electrodes 50, 52. Accordingly, it may be desirableto utilize a conductive element that increases the potential number ofpoints of electrical connection between the carbon fibers and theelectrodes. Additionally, it may be desirable to utilize a conductiveelement that may be more likely to contact the ends of the carbon fibersthat are not covered in sizing. For instance, in the present instance,the electrodes 50, 52 comprise a conductive metal mesh, such as coppermesh. The metal mesh provides multiple points of contact along thelength of the end of each resistive element 40. The configuration of thecopper mesh may vary, however, preferably the mesh is configured so thatthe open portion of the mesh (the area of pores per square inch of mesh)is greater than the closed portion of the mesh (i.e. the area of thecopper per square inch of mesh). Additionally, the open portion of themesh may be greater than approximately 60%. In some configurations, theopen portion of the mesh may be greater than approximately 70%.

As described above, the heating layer 30 comprises a plurality of carbonfibers electrically connected with conductive elements, such as theinput electrode 50 and the output electrode 52. The carbon fibers areembedded within a matrix material, such as a thermoplastic. Similarly,the structural layers 25, 26 may also be formed of carbon fiberreinforced thermoplastic material. Therefore, the carbon fibers in thestructural elements are also electrical conductive. To ensure that theelements of the heating layer 30 do not electrically connect with thecarbon fibers in the structural layers 25, 26, the laminate may includean insulative layer. The insulative layer 28 is disposed between theheating layer 30 and the structural layers. In particular, the laminatemay include a first insulation layer 28 between the upper face of theheating layer 30 and the upper structural layer 25 and a secondinsulation layer 28 between the lower face of the heating layer and thelower structural layer 26. The insulation layer 28 provides electricalinsulation between the structural layers and the electrically conductiveelements (e.g. resistive elements 40, input electrode 50, outputelectrode 52) of the heating layer 30.

The insulation layer 28 may comprise any of a variety of electricallyinsulative materials. Preferably, the insulation layer 28 comprises athermoplastic material. In the present instance, the insulation layercomprises one or more lamina of glass reinforced thermoplastic.

As discussed above, each of the structural layers 25, 26, the heatinglayer 30 and the insulative layers 28 may comprise layers of reinforcedthermoplastic composite materials. Accordingly, the upper structurallayer 25, the lower structural layers, the heating layer and anyinsulation layer can be integrally connected by fusing the layers.Specifically, the layers may be consolidated by applying sufficient heatto raise the layers above the melting point of the thermoplastic matrixand applying sufficient pressure to fuse the layers together. In thisway, the heating layer 30 is embedded within the laminate between theupper and lower structural layers 25, 26.

It should be noted that the thickness of the layers in the Figures arenot to scale and in some instances the thickness is exaggerated forillustration purposes only. For instance, in FIG. 1, the heating layer30 is depicted as having a thickness greater than the insulation layers28. However, the heating layer 30 may be just a single lamina ofcomposite material. Similarly, the insulation layer may be a singlelamina of composite material. Further still, as noted above, eachinsulation layer 28 may comprises one or more lamina. Additionally, thethickness of the structural layers may be significantly thicker than thethickness of the thickness of the heating layer. For instance, the upperlayer 25 may be formed from three or more laminae of reinforcedcomposite material so that the structural layers are substantiallythicker than the thickness of the heating layer. Additionally, as shownin FIG. 2, the heating layer 30 is not necessarily a continuous layerextending the entire length and width of the laminate as shown inFIG. 1. Instead, the heating layer 30 may be embedded within theinsulation layers 28.

Referring now to FIG. 3, the heated laminate 20 described above may beincorporated into a system for providing controlled heating. The systemincorporates a power source 60 that is connected to heated laminate 20via a controller 70. The controller may be any of a variety ofelectronic controllers, including but not limited to a P, PD, PI, PIDcontroller or a microprocessor. The electrodes 50, 52 of the heatedlaminate are connected with the controller 70 so that the controllercontrols the flow of electricity to the laminate. In response tosignals, the controller 70 closes the circuit between the heatingassembly 30 and the power source to turn the heating layer ON.Similarly, in response to signals, the controller may disconnect theheating layers from the power source to turn the heating layer OFF.Similarly, the controller may be configured to increase or decrease acharacteristic of the electricity, such as by increasing or decreasingthe current provided to the heating layer.

The controller may control the flow of electricity to the heatingassembly based on a variety of controls. For instance, the system mayinclude a manually operable switch so that the controller controls thesystem in response to actuation of the switch (i.e. the heating layer 30is connected with the power source when the switch is ON anddisconnected when the switch is OFF). Additionally, the system 10 mayinclude a feedback loop so that the controller controls the system inresponse to the feedback. For instance, the system may include a sensorthat is used to detect a characteristic of the assembly and thecontroller may control the operation of the heating layer in response tothe detected characteristic. An exemplary sensor is a sensor fordetecting a characteristic indicative of the formation of ice on thelaminate 20. For instance, the system may include an ice detector suchas an optical transducer probe configured to detect the presence of iceon the laminate, such as the upper surface 22. The ice detector isconnected to the controller to provide signals to the controllerindicative of the presence of ice. If the signal indicates the presenceof ice, the controller may connect the heating layer 30 with the powersource to turn the heating layer ON. Similarly, if the controllerreceives a signal from the sensor 75 indicating a lack of ice, thecontroller may disconnect the heating layer from the power source toturn the heating layer OFF.

Configured as described above, the system may be configured to raise thetemperature of one or more surfaces of the aerostructure to impede theformation of ice on the aerostructure or to melt ice formed on theaerostructure. Specifically, the first electrode and the electricallyconductive carbon fibers are connected such that electric power appliedto the first electrode is conducted to the electrically conductivecarbon fibers to provide resistive heating sufficient for the heatinglayer to achieve a temperature increase of at least 50 degreesFahrenheit or approximately 30 degrees Celsius. Optionally, the carbonfibers of the heater layer are connected with the first electrode suchthat electric power applied to the first electrode is conducted to theelectrically conductive carbon fibers to provide resistive heatingsufficient for the heating layer to achieve a temperature increase of100 degrees Fahrenheit or approximately 55 degrees Celsius. Furtherstill, the carbon fibers of the heater layer may be connected with thefirst electrode such that electric power applied to the first electrodeis conducted to the electrically conductive carbon fibers to provideresistive heating sufficient for the heating layer to achieve atemperature increase of 200 degrees Fahrenheit or approximately 110degrees Celsius.

The heated laminate 20 may be formed using a variety of processes. Thedetails of a process of forming the heated laminate from a plurality ofreinforced thermoplastic layers will now be described.

A plurality of layers of carbon fiber reinforced thermoplastic tape arelaid over top of one another to form a plurality of plies that form thelower structural layer 26. The fiber orientation in the plies arevaried. For example, the bottom layer may be formed of four pliesoriented at 0, +45°, 90°, −45°. One or more layers of fiberglassreinforced thermoplastic are then laid over the bottom four layers. Twoelectrodes in the form of elongated electrically conductive metal stripssuch asof metal mesh are spaced apart from one another and arranged onthe fiberglass layers running from a first end toward a second end. Thecarbon fiber reinforced thermoplastic tape forming the resistiveelements 30 are then overlaid on the fiberglass layers so that one endof the carbon fiber tape overlies the first length of copper mesh andthe second end of the carbon fiber tape overlies the second length ofcopper mesh. Additionally, the carbon fiber tape may be spliced to forma serpentine pattern, with metal mesh overlying the joints betweenadjacent pieces of the carbon fiber tape to form a continuous electricalpath. After the heating elements are arranged over the lower fiberglasslayers and the copper mesh, two layers of fiberglass reinforcedthermoplastic are laid over the heating elements. Four layers of carbonfiber tape similar to the bottom four layers are then laid over thefiberglass layers. The top layers of carbon fiber thermoplastic tapeform the upper structural layer. Like the lower structural layer, theorientation of the fibers in the plies of the upper structural layer isvaried. For instance, the plies of the upper structural layer may beformed of four plies oriented at 0, +45°, 90°, −45°. In this exemplarylaminate, the carbon fiber layers of the upper structural layer, theheating layer and the lower structural layer are formed of PEEK/AS4carbon fiber reinforced unidirectional tape and the insulation layersare formed of PEEK/S2 fiberglass reinforced thermoplastic unidirectionaltape.

The laminate is then consolidated by heating the assembled plies underpressure. For instance, the assembly may be heated up to a temperatureabove the melting temperature. The pressure is then removed and theconsolidated laminate is cooled to ambient temperature.

A laminate formed according to such process was then connected with apower source. In particular, a 28 VDC 8 amp power source was connectedwith the laminate. Upon application of power to the laminate, theheating element provided sufficient resistance to provide a voltage dropof 25 V between the input electrode and the output electrode. Theresulting resistance heating provided a temperature increase of 230°Fahrenheit. This temperature increase was below the glass transitiontemperature of the matrix material in the laminate and substantiallybelow the melting temperature.

In the foregoing description, the laminate is described as a flat panellaminate. However, it should be understood that the invention is notlimited to flat panel structures. For instance, the heated laminate maybe used in a variety of structures in a variety of fields and may haveparticular application in the field of aerospace to provide iceprotection systems for a variety of components, including, but notlimited to airframes, nacelles and airfoils, such as wings, elevatorsetc. The laminate 20 described above may be formed into a curvedstructure and incorporated into a system similar to system 10 describedabove to provide a heated laminate structure.

For example, an exemplary laminate 120 forming an aerostructure isillustrated in FIGS. 4-5. Except as described further below, thecharacteristics of the laminate 120 are similar to the characteristicsof the laminate 20 described above. The illustrated laminate 120 forms asection of the nacelle that forms a leading edge around the intake ofthe jet engine. The laminate 120 is formed so that the heating layer 130wraps over the leading edge of the structure. In particular, thelaminate comprises a convex curve having an apex 121, an upper surface122 and a lower surface 123.

The laminate 120 is formed similar to the laminate 20 described above.In particular, the laminate includes an upper structural layer 125formed of a plurality of reinforced composite laminae and a lowerstructural layer 126 formed of a plurality of reinforced compositelaminae. A heating layer 130 is embedded between the upper and lowerstructural layers 125, 126. Additionally, an upper electricallyinsulative layer 128 may be disposed between the heating layer and theupper structural layers and a lower insulative layer may be disposedbetween the heating layer and the lower structural layers. The heatinglayer comprises a plurality of resistive elements forming an electricalpath between an input electrode 150 and an output electrode 152. Theheating layer may be any of a variety of elements, and in the presentinstance, the heating element is formed of a non-metal conductiveelement, such as carbon fiber.

The heating layer may be configured to overlie either the upper or lowersurfaces of the laminate, however, in the present instance, the heatinglayer is configured to overlap both the upper and lower surfaces. Morespecifically, the heating layer 130 is arranged within the lamina sothat a portion of the resistive element 140 overlies the upper surface.Additionally, the resistive element is arranged so that a portion of theresistive element extends over the apex 121 of the curve and then overthe lower surface 123. In this way, the heating element wraps around theleading edge of the nacelle.

The layers of the nacelle are consolidated to form an integral laminatewith the heating layer embedded within the laminate. For instance, thelaminate 120 may be formed of reinforced thermoplastic compositematerials as described above so that the laminate is consolidated byheating the assembled layers to an elevated temperature under pressure.

As described above, the system illustrated in FIG. 3 may incorporate thecomposite element 120 illustrated in FIGS. 4-5 instead of the compositeelement 20 illustrated in FIG. 3. Similarly, FIGS. 6-9 illustrate analternate composite element 220 that can be incorporated into the systemillustrated in FIG. 3 instead of composite element 20. Accordingly, thedetails of composite element 220 will now be described in detail.

The composite element 220 may include an upper structural layer 225, alower structural element 226 and a heating layer 230 disposed betweenthe upper structural layer 225 and the lower structural layer. Thestructure of the upper and lower structural layers 225, 226 may vary. Inparticular, the structural layers 225, 226 may be formed of one or morelayers of reinforced composite material, such as carbon fiber orfiberglass reinforced material. In the present instance the structurallayers 225, 226 are formed of the same material. For example, in thepresent instance, a plurality of layers of carbon fiber reinforcedthermoplastic tape are laid over top of one another to form a pluralityof plies that form the lower structural layer 226. The fiber orientationin the plies are varied. For example, the bottom layer may be formed offour plies of carbon fiber reinforced thermoplastic oriented at 0, +45°,90°, −45°. The upper structural layer 225 may be formed similar to thelower layer 226. The heating layer 240 comprises one or more resistiveelements 240 formed of carbon fiber reinforced thermoplastic.Preferably, the resistive element(s) are formed of carbon fiberreinforced thermoplastic material that is substantially similar to thematerial from which the structural layers 225, 226 are formed.

The heating layer 230 is comprised of a plurality of resistive elements.As described previously, the heating layer may be formed of a singleresistive element 40, 140. Alternatively, the heating layer 230 mayinclude a plurality of heating zones that can be independentlycontrolled. For instance, in the embodiment illustrated in FIGS. 6-9,the heating layer 230 includes three heating zones 250, 270 and 290. Asdescribed further below, the heating layer 240 comprises a plurality oflayers and the three heating zones are spread across two differentlayers in the heating layer. However, it should be appreciated that theheating layer may be a single layer or may be more than two layers.

Referring now to FIG. 7-8 details of the heating layer will now bedescribed in greater detail. FIG. 8 illustrates the details of the firstzone 250 of the heating element most clearly. The first zone includesone or more resistive elements 255 extending between a plurality ofconductive elements 265, 266. The number of resistive elements 255 mayvary, however, in the present instance, the first zone 250 includes fiveresistive elements designated 255A-255E. The resistive elements may havedifferent configurations, however in the present instance, eachresistive element 255A-255E is substantially similar having asubstantially similar resistive value. Accordingly, the followingdescription of resistive element 255 applies to each of resistiveelements 255A-255E.

Resistive element 255 comprises three sections: a lead 257 at a firstend, a tail 258 at a second end, and a body section 260 extendingbetween the lead and the tail. The lead 257 forms an electricalconnection with conductive element 265 and the tail forms an electricalconnection with conductive element 266. The body provides an electricalpathway between the lead and the tail. In particular, the body 260provides an electrical pathway having sufficient resistance to providejoules effect heating sufficient to raise the temperature of the heatinglayer 230 when current is passed through the body.

The resistive elements 255 may be configured in any of a variety ofconfigurations. For instance, the body 260 may be a generally straightor linear body extending between the first conductor 265 and the secondconductor 266. In this way, zone one may comprises a plurality ofstraight resistive elements extending between the first conductor 265and the second conductor 266. However, in the present instance, the body260 of resistive element 255 comprises a convoluted pathway to increasethe effective heating area of each heating element. Specifically, thebody 260 may comprise a serpentine configuration having a plurality oflegs. In particular, the serpentine path may include a plurality ofgenerally or substantially parallel legs. The serpentine path preferablyis constrained within a single layer or lamina so that the serpentinepath of the body does not cross or overlap itself at any point betweenthe lead 257 and the tail 258. In other words, the body 260 may have anominal thickness that is substantially constant along the length of thebody. Additionally, the body may form a convoluted reciprocal path, butthe body does not cross over itself forming a point or area in which theresistive element has a thickness that is twice the nominal thickness ofthe body.

Preferably, the resistive elements 255 are connected in parallel betweenthe first and second conductive elements 265, 266. In this way, thefirst zone 250 of the heating element 230 comprises a first circuit inwhich the conductor 265 forms a first lead or electrode and the secondconductor 266 forms a second lead or electrode with the resistiveelements electrically connecting the two electrodes. When the twoelectrodes 265, 266 are connected to a power supply current passesthrough the resistive elements 255 to create joules effect heating. Inthe embodiment illustrate in FIG. 8, the resistive element is acontinuous electrical pathway between the two conductive elements 265,266. In particular, the resistive elements comprise a plurality ofcontinuous unidirection carbon fibers forming a convoluted electricalpath, such as a serpentine path, between the first electrode 265 and thesecond electrode 266. In the present instance, the carbon fibers areembedded within a matrix of thermoplastic material. More specifically,preferably the carbon fibers are embedded within a thermoplastic resinthat is substantially the same as the thermoplastic material forming thematrix material of the structural layers. For instance, the resistiveelement may be formed of a narrow unidirectional tape, such as 0.12″wide AS4D/PAEK unidirectional pre-preg tape. An exemplary unidirectionalcarbon fiber tape is TC1225 sold by Tencate as referenced previously.

In particular, preferably the resistive element 255 comprises aunidirectional material such that substantially all of the carbon fibersin the material are parallel. More specifically, preferablysubstantially all of the carbon fibers have a first end and a second endso that substantially all of the carbon fibers extend the entire lengthof the resistive element 255 from the lead 257 to the tail 258. In thiscontext, substantially all of the carbon fibers means at least 90% ofthe carbon fibers in the resistive element.

The resistive element 255 may be formed into a convoluted shape by heatforming the unidirectional fiber tape. Specifically, a length ofunidirectional tape may be heated to a sufficient temperature to causethe thermoplastic material to soften. For example, the tape may beheated to a temperature above the glass transition temperature Tg forthe thermoplastic matrix material for the tape. Further still, it may bedesirable to heat the tape to a temperature significantly higher thanthe glass transition temperature, such as at or above the meltingtemperature Tm for the thermoplastic matrix material (if thethermoplastic has a melt temperature). In the example of a PAEK or PEEKthermoplastic resin, the tape may be heated to above approximately 300°C. Once the tape is heated above Tm, the tape is wrapped around a formthat provides a convoluted shape. Formed in this way, the resistiveelement forms a convolute path in which the resistive element does notcross over itself so that the entire length of the resistive element issubstantially the same as a single thickness of the tape. After the tapeis formed to the convoluted shape, the tape is cooled to below the glasstransition.

As described above, the resistive element 255 provides an electricalpath. Because the carbon fibers are unidirectional, the electrical pathfollows the configuration of the resistive element from the firstelectrode 265 to the second electrode 266. For instance, as shown inFIG. 8, each resistive element follows a convoluted path, such as aserpentine path. The resistive element 255 has a central axis thatextends from the lead 257 to the tail, following the serpentine path.The carbon fibers in the resistive element follow the central axis. Inother words, all or substantially all of the carbon fibers in theresistive element are substantially parallel to one another andsubstantially parallel to the central axis.

The resistive element 255 is connected with the conductive elements 265,266 so that the carbon fibers of the resistive element are electricallyconnected with the conductive elements. More specifically, theconductive elements directly contact the carbon of the carbon fibers. Inparticular, it should be noted that the carbon fibers may have acoating, referred to as sizing. Preferably, the conductive elements 265,266 directly contact the carbon fiber so that the carbon fiber providesthe electrical path between the conductive elements 265, 266. Morespecifically, if the carbon fibers include a sizing (such as a coatingto promote promoting bonding between the carbon fibers and thethermoplastic resin) the sizing may be significantly less conductivethat the carbon fiber so that the carbon fiber conducts at least themajority and preferably substantially all of the electricity flowingthrough the resistive element between the first conductor and the secondconductor.

Configured as describe above, in an exemplary configuration of the firstzone 250, each resistive element 255A-255E provides approximately 46ohms of resistance. In this way, the nominal wattage of the first zoneat 100 volts AC is approximately 1100 watts. Accordingly, the heatingelement 230 provides sufficient joules effect heating to raise thesurface temperature of the outer surface of upper structural element 225without raising the temperature of the element 220 above the glasstransition temperature for the thermoplastic matrix material in theelement.

Referring now to FIG. 7, the details of the second and third heatingzones 270, 290 will now be described. The second heating zone 270 isconfigured substantially similarly to the first heating zone 250.Specifically, the second heating zone 270 comprises a plurality ofresistive elements 275A-275E. Each of the resistive elements 275includes a lead 277 electrically connected with a third conductiveelement 285 and a tail electrically connected with a fourth conductiveelement 286. The resistive elements 275A-275E are connected in parallelwith the two conductive elements 285, 286.

The resistive elements 275A-275E may be formed substantially identicallywith the resistive elements 255A-255E of the first heating zone 250.However, it may be desirable to vary the configuration of the resistiveelements in the second heating zone to vary the heating characteristicsof the second heating zone. For instance, in the present instanceresistive elements 275 are substantially longer than resistive elements255. In particular, the body 280 of resistive element 275 may beapproximately twice as long as the body 260 of resistive element 255. Inthis way, if resistive element 275 is formed of the same material asresistive element 255 then resistive element 275 will have substantiallyhigher resistance than resistive element 255. In this way, at the samevoltage, the nominal wattage of the second zone is significantly lessthan the nominal wattage of the first zone 250. For example, at 100volts AC the wattage of the second heating zone may be approximately 800watts as opposed to nominally 1100 watts for the first heating zone.

FIG. 7 further illustrates the third heating zone 290, which includes aplurality of resistive elements 295A-295E connected in parallel to thefourth conductive element 286 and a fifth conductive element 287.Although the resistive elements 295A-295E may be configured differentlyfrom resistive elements 275A-275E, in the present instance resistiveelements 295A-295E are substantially identical to resistive elements275A-275E.

As shown in FIG. 7, the first heating zone 250 is on a separate layerthan the second and third heating zones 270 290. In particular, thethree heating zones are configured so that the body 260 of eachresistive element 255A-255E is positioned below the second and thirdheating zones so that the body of each resistive element 275, 295 doesnot overlie the body 260 of each resistive element in the first heatingzone. In this way, the heating area provided by the second and thirdheating zones does not substantially overlap the heating area created bythe first heating zone.

As shown in FIG. 7, the different layers of the heating element areseparated by insulative layers. For instance, one or more insulativelayers may be positioned between the layer having the first heating zone250 and the layers having the second and third heating zones. Inparticular, an insulative layer formed of fiberglass reinforcedthermoplastic material may overlie the first heating zone toelectrically isolate the first resistive elements 255 from the secondand third resistive elements 275, 295. The insulative layers may beformed of S2 PEEK layers as described above.

The laminate 220 is consolidated by heating the assembled plies 225,226, 230 under pressure. For instance, the assembly may be heated up toa temperature above the melting temperature. The pressure is thenremoved and the consolidated laminate is cooled to ambient temperature.

A laminate formed according to such process can then be connected with apower source to create a circuit similar to the circuit shown in FIG. 3.However, since the laminate 220 in FIGS. 6-9 includes three heatingzones, the circuit may include one or more switches to control the powersupplied to each of the three heating zones. The switches allow power tobe supplied independently to one or more of the three heating zones 250,270, 290. For example, when the laminate illustrated in FIGS. 6-9 isformed into an aerostructure, the different heating zones may bepositioned and configured to apply heat to different parts of theaerostructure. In the instance of an airfoil, the airfoil may have aleading edge, an upper surface and a lower surface. The three heatingzones may be positioned so that the first heating zone 250 overlies theleading edge of the airfoil, the second heating zone may overlie theupper surface and the third heating zone overlies the lower surface ofthe airfoil. In such a configuration, the resistive elements of thethree heating zones 250, 270, 290 are configured to provide sufficientheating to raise the temperature of one or more surfaces of the laminateby at least 50 degrees Fahrenheit or approximately 30 degrees Celsius.For example, the first heating zone may be configured an oriented toraise the temperature of the outer surface of the leading edge by atleast approximately 50 degree Fahrenheit or approximately 30 degreesCelsius. Similarly, the second zone 270 may heat the upper surface andthe third zone may heat the lower surface.

The system may also include a plurality of sensors. For instance, thesystem may include a first sensor sensing a characteristic of a firstarea, a second sensor sensing a characteristic of a second area and athird sensor sensing a characteristic of a third area. Based on thesignals received from the three sensors, the system may independentlycontrol the power supplied to each of the three heating zones. In oneexample, the first sensor detects the presence of ice on the leadingedge and the system controls the power supplied to the first heatingzone in response to the signal from the first sensor. In particular, ifthe first sensor detects a characteristic indicative of the presence ofice the system may increase the power supplied to the first heating zone250 to increase the temperature of the leading edge. Additionally, thesystem may control the power supplied to the first heating zone byreducing or discontinuing the power supplied to the first heating zoneif the first sensor detects a characteristic indicative of a lack of iceon the leading edge. In this way, the system may control the heating ofthe first zone to increase or decrease the temperature of the leadingedge to impede the formation of ice or to melt ice already formed on theleading edge. Similarly, in response to signals received from the secondsensor, the system may control the power supplied to the second heatingzone to impede the formation of ice or to melt ice already formed on theupper surface. Further still, in response to signals received from thethird sensor the system can control the power supplied to the thirdheating zone to impede the formation of ice or to melt ice alreadyformed on the lower surface.

It will be recognized by those skilled in the art that changes ormodifications may be made to the above-described embodiments withoutdeparting from the broad inventive concepts of the invention. It shouldtherefore be understood that this invention is not limited to theparticular embodiments described herein, but is intended to include allchanges and modifications that are within the scope and spirit of theinvention as set forth in the claims.

1. A heated aerostructure, comprising: a composite structure,comprising: a carbon fiber reinforced thermoplastic upper structurallayer; a carbon fiber reinforced thermoplastic lower structural layer; areinforced thermoplastic heater layer, comprising: a plurality ofelectrically conductive non-metallic fibers; a first electrodeelectrically connected with the conductive non-metallic fibers; and asecond electrode electrically connected with the conductive non-metallicfibers, so that the conductive non-metallic fibers provide an electricalpathway between the first electrode and the second electrode; acontroller connected with a sensor and an electrical power source forcontrolling the power provided to the first electrode; wherein the firstelectrode and the conductive non-metallic fibers are connected such thatelectric power applied to the first electrode is conducted to theelectrically conductive non-metallic fibers to provide resistive heatingsufficient to heat the composite structure to impede the formation ofice on the composite structure.
 2. The heated aerostructure of claim 1wherein the plurality of electrically conductive fibers of the heaterlayer comprise unidirectional carbon fiber reinforced thermoplastic. 3.The heated aerostructure of claim 2 wherein the electrically conductivefibers have a first end electrically connected with the first electrodeand a second end electrically connected with the second electrode andsubstantially all of the carbon fibers extend continuously from thefirst end to the second end.
 4. The heated aerostructure of claim 1wherein the controller is operable to control the electrical powerprovided to the first electrode in response to signals received from thesensor.
 5. The heated aerostructure of claim 4 wherein the electricallyconductive fibers have a first end electrically connected with the firstelectrode and a second end electrically connected with the secondelectrode and substantially all of the carbon fibers extend continuouslyfrom the first end to the second end.
 6. The heated aerostructure ofclaim 5 wherein the heater layer comprises a convoluted path between thefirst and second electrodes.
 7. The heated aerostructure of claim 5comprising a second heater layer independently operable from the heaterlayer and a third electrically insulative layer insulating the secondheater layer from the heater layer.
 8. The heated aerostructure of claim1 wherein the thermoplastic of each of the heater layer, the upper layerand the lower layer are fused with the thermoplastic in adjacent layers.9. The heated aerostructure of claim 1 wherein the third glasstransition temperature is within 25% of the fourth and fifth glasstransition temperatures.
 10. A heated aerostructure, comprising: acarbon fiber reinforced thermoplastic upper layer; a carbon fiberreinforced thermoplastic lower layer; a carbon fiber reinforcedthermoplastic heater layer, wherein the upper layer, lower layer andheater layer are consolidated to form a laminate; wherein the heaterlayer comprises a plurality of electrically conductive carbon fibers andwherein the heater layer is configured so that the electricallyconductive carbon fibers of the heater layer are connectable with apower source so that electricity can flow through the electricallyconductive carbon fibers of the heater layer to provide resistiveheating sufficient for the heating layer to heat at least a portion ofthe laminate at least 50 degrees Fahrenheit.
 11. The heatedaerostructure of claim 10 wherein the electrically conductive carbonfibers form a unidirectional carbon fiber reinforced thermoplasticlayer.
 12. The heated aerostructure of claim 11 wherein the electricallyconductive carbon fibers have a first end electrically connected with afirst electrode and a second end electrically connected with a secondelectrode and substantially all of the carbon fibers extend continuouslyfrom the first end to the second end.
 13. The heated aerostructure ofclaim 12 wherein the heater layer comprises a convoluted path betweenthe first and second electrodes.
 14. The heated aerostructure of claim12 comprising a sensor operable to sense a characteristic indicative ofthe presence of ice on the upper layer.
 15. The heated aerostructure ofclaim 13 comprising a controller connected with the sensor and anelectrical power source for controlling the power provided to the heaterlayer.
 16. The heated aerostructure of claim 14 wherein the controlleris operable to control the electrical power provided to heater layer inresponse to signals received from the sensor.